Ignition coil assembly
a coil and assembly technology, applied in the direction of coils, electromagnets, other installations, etc., can solve the problems of voids in the material, voids that may not offer enough dielectric strength, and need spaces to allow the proper flow of epoxy within the sub-assembled coils
Active Publication Date: 2015-08-04
DELPHI TECH IP LTD
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- Abstract
- Description
- Claims
- Application Information
AI Technical Summary
Benefits of technology
The present invention relates to an ignition coil assembly and a method for assembling it. The assembly includes a magnetic core and a spool that defines a cavity. A coil is wound around the spool. The spool includes a portion that decreases in size when the coil is wound around it, which increases the space between the coil and the spool to inject insulating material without creating voids in the insulation. The method involves inserting the spool and coil into another spool and injecting insulating material into the space between the coil and the inner surface of the other spool. The technical effect of the invention is to provide an improved design for an ignition coil assembly that allows for efficient insulation without creating voids.
Problems solved by technology
One disadvantage of epoxy resin-based materials, where filler content is part of the formulation, is the need for spaces to allow the proper flow of epoxy within coil sub assembles when it is poured or injected into the ignition coil assembly.
The lack of spaces to allow the proper flow of epoxy may create voids in the material after it hardens.
These voids may not offer enough dielectric strength to insulate a high voltage in the secondary coil from a lower voltage in the primary coil.
This may cause arcing between the primary coil and the secondary coil that may result in a lower secondary voltage output and poor energy delivery from the ignition coil assembly.
Arcing may also damage the ignition coil assembly.
Method used
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Embodiment Construction
[0022]It may be desirable to minimize the space between the components of an ignition coil assembly to minimize the overall size of the ignition coil assembly. It has been observed that bubbles are more likely to form when injecting a thick electrically insulating material, such as an uncured epoxy resin material or a molten plastic material into a smaller space than when injecting the material into a larger space. The bubbles may form voids when the electrically insulating material hardens. These voids may diminish the electrical insulation properties of the material. The ignition coil assembly set forth herein includes features that help to increase the size of a space between internal components, thereby decreasing the likelihood of voids in the electrically insulating material, without increasing the overall size of the ignition coil assembly.
[0023]An ignition coil assembly may be constructed by inserting a magnetic core within a first spool around which a first coil is wound. T...
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Abstract
An ignition coil assembly and a method of assembling the ignition coil assembly including a first spool, a first coil, and a second spool. The first coil is wound around a first spool outer surface. The first spool and the first coil are disposed within a cavity of the second spool and an electrically insulating material injected into an annular space defined between a first coil outer surface and a second spool inner surface. The first spool is configured to allow a decrease of a circumference of the first spool when the first coil is wound around an outer surface of the first spool. Decreasing the circumference of the first spool increases the annular space sufficient to inject the electrically insulating material into the annular space without creating substantial voids in the electrically insulating material.
Description
TECHNICAL FIELD OF INVENTION[0001]The invention generally relates to an ignition coil assembly for a spark ignition internal combustion engine, and more particularly relates to features of an ignition coil assembly that help to prevent voids in an electrically insulating material between the primary coil and the secondary coil.BACKGROUND OF INVENTION[0002]Ignition coil assemblies typically have an electrically insulating material between the primary coil and the secondary coil. Earlier ignition coil assembly designs used liquid oil as the electrically insulating material. Some more recent ignition coil assembly designs use epoxy resin-based materials as an electrically insulating material due to improved mechanical properties. Since epoxy resin-based materials typically harden, they may offer additional mechanical support to ignition coil components.[0003]One disadvantage of epoxy resin-based materials, where filler content is part of the formulation, is the need for spaces to allow...
Claims
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IPC IPC(8): H01F27/02H01F41/12F02P3/04H01F38/12H01F27/30H01F5/02
CPCH01F41/127F02P3/04H01F38/12H01F41/0616H01F2005/025Y10T29/49071H01F41/066H01F2038/122Y10T29/49073
InventorARROYO, LUIS ARTUROGALICIA, JOSE J.
OwnerDELPHI TECH IP LTD